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Wire Composition: Its Effect on Metal Disintegration and Particle Formation in Twin-Wire Arc-Spraying Process

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Abstract

The wire tips in twin-wire arc-spraying (TWAS) are heated in three different zones. A high-speed camera was used to observe the melting behavior, metal breakup, and particle formation under different operating conditions. In zone (I), the wire tips are melted (liquidus metal) and directly atomized in the form of smaller droplets. Their size is a function of the specific properties of the molten metal and the exerting aerodynamic forces. Zone (II) is directly beneath zone (I) and the origin of the extruded metal sheets at the wire tips. The extruded metal sheets in the case of cored wires are shorter than those observed while using solid wires. In this study, the effects of adjustable parameters and powder filling on melting behavior, particle formation, and process instability were revealed, and a comparison between solid and cored wires was made. The findings can improve the accuracy of the TWAS process modeling.

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Acknowledgments

The authors gratefully acknowledge the financial support of the DFG (Deutsche Forschungsgemeinschaft) within the collaborative research Centre SFB708/TP-B3.

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Authors and Affiliations

  1. Institute of Materials Engineering, Technische Universität Dortmund, Dortmund, Germany

    W. Tillmann & M. Abdulgader

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  1. W. Tillmann
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  2. M. Abdulgader
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Correspondence to M. Abdulgader.

Additional information

This article is an invited paper selected from presentations at the 2012 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Thermal Spray 2012: Proceedings of the International Thermal Spray Conference, Air, Land, Water, and the Human Body: Thermal Spray Science and Applications, Houston, Texas, USA, May 21-24, 2012, Basil R. Marple, Arvind Agarwal, Laura Filofteia-Toma, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and André McDonald, Ed., ASM International, Materials Park, OH, 2012.

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Tillmann, W., Abdulgader, M. Wire Composition: Its Effect on Metal Disintegration and Particle Formation in Twin-Wire Arc-Spraying Process. J Therm Spray Tech 22, 352–362 (2013). https://doi.org/10.1007/s11666-012-9870-y

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  • DOI: https://doi.org/10.1007/s11666-012-9870-y

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